Design, 3D print and assemble a working drone quadcopter.

LEARNING OBJECTIVESBy the end of this workshop, the student will be able to:

• Identify and apply the steps in the design process.

• Gather and apply information pertinent to design planning.

• Plan and organize the project.

• Create concept and scaled sketches of design ideas.

• Use appropriate design tools to create CAD drawings and full-scale 3D printed models.

• Reflect on their experience with the design process using a suitable oral and/or written report.

ESSENTIAL QUESTIONS • What makes a drone feasible?

• Why are drones relevant to today’s society?

• How will drones be utilized in the future?

• How does the use of drones affect moral responsibility?

ESSENTIAL DETAILS When developing the design consider weight, electric motor efficiency, propeller diameter, tolerances and the overall cost of the components. The drone must:

• Operate via a controller

• Include four electric motors

• Have on/off switch

• Fit within the following maximum overall dimensions:

− Length: 24 inches

− Width: 24 inches

− Height: 8 inches

The following parts of the drone can be 3D printed:

• Arm

• Battery compartment

• Landing gear

• Propeller cover

• Center hub and plates

Note: Two online retailers have been included for purchase of drone components. Following is a list of required components

REQUIREMENTS

POWER PACK D (STANDARD QUADCOPTER)

Pack Includes:

• (4) Motors – Emax 2213-935kv (CW Threaded Shaft)

• (4) ESCs – BL Heli 20 amp XT-60

• (4) M6 Aluminum Lock nuts - (Standard/CW threaded)

• (4) Propellers – 10 x 4.5 CW

• (4) Propellers – 10 x 4.5 CCW

• (1) Battery Lead – XT60

• (1) FT Allen Driver

• (1) FT Screwdriver

• (1) Flite Test Adjustable Lanyard

L E S S O N G U I D E

Drone Quadcopter

Level Advanced

Academic Connections Engineering, Aerodynamics, Design Thinking, Presentation and Communication

Core Concepts Computer Aided Design (CAD), Design, Design Optimization, Assembly and Testing

Duration 6-8 weeks

LINKS TO PURCHASE:

BATTERY PACK

LUMENIER 2250MAH 4S 35C LIPO BATTERY

Links to purchase:

CONTROLLER BOARD

CRIUS MWC MultiWii SE V2.6 Standard Flight Controller Board X Mode No FTDI For RC Multi Quadcopter UFO

Links to purchase:

RECEIVER

RadioLink T6EHP-E 2.4G 6CH Transmitter w/ R7EH Receiver

Links to purchase:

BATTERY CHARGER

Hitec/RCD 44245 Hitec RDX1 AC/DC Charger/Discharger

Links to purchase:

store.flitetest.com/power-pack-d-standard-quadcopter/rotorbuilds.com/part/95

store.flitetest.com/lumenier-2250mah-4s-35c-lipo-batteryhobbyking.com/en_us/batteries.html?gclid=CKzUnaq7odMCFQILaQod1WYPag&gclsrc=aw.ds

www.amazon.ca/MultiWii-Standard-Flight-Controller-Quadcopter/dp/B01HBA4S0E/ref=sr_1_8?ie=UTF8&qid=1477487877&sr=8-8&keywords=multiwii

www.xt-xinte.com/F05300.html

www.robotshop.com/ca/en/radiolink-t6ehp-e-24g-6ch-transmitter-r7eh-receiver.html?gclid=CjwKEAjw19vABRCY2YmkpO2OzTsSJAAzEt8sqfszcKobvIPKQmRl2926k9eiqGzTj7RWowujkAXD-BoCce3w_wcB

www.banggood.com/FlySky-FS-i6-2_4G-6CH-AFHDS-RC-Transmitter-With-FS-iA6-Receiver-p-922606.html?utm_source=google&utm_medium=cpc_ods&utm_content=Heidi&utm_campaign=srcplane-parts-ds-fr&gclid=CI6Qyuy7odMCFQEHaQod0pIOTA

www.newegg.com/Product/Product.aspx?Item=9SIA22K4RH8299

https://www.google.ca/search?q=Hitec/RCD+44245+Hitec+RDX1+AC/DC+Charger/ Discharger&espvd=2&source=univ&tbm=shop&tbo=u&sa=X&ved=0ahUKEwjv8JmAv KHTAhXh3YMKHZhgCaEQsxgIlQE&biw=1349&bih=689&gws_rd=ssl#spd= 862849747430606807

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DISTRIBUTION BOARD

Hobby King Quadcopter Power Distribution Board

Links to purchase:

BREAKOUT CIRCUIT BOARD

FTDI Basic Breakout - 5V - With 6-pin header

Links to purchase:

DESIGN PROCESS: RESEARCHTo facilitate research, students are encouraged to visit reputable design sites to explore a variety of drone quadcopter designs. The following website and PDF document are excellent resources to support project workflow.

Build Your Own Drone: www.airspacemag.com/flight-today/build-your-own-drone-180951417

Drones Take Off: commoncore.scholastic.com/sites/default/files/Drones%20Take%20Offpdf

DESIGN PROCESS: CONCEPTConcept sketches: Refer to the “Designer’s Toolkit” section on Drawing Standards.

The top and side views are most important to sketch during this process.

DESIGN PROCESS: DEVELOPMENT

2D AND 3D CAD MODELING

Concept sketches can be used to develop both the 2D and 3D CAD models. When transferring information from initial sketches, ensure all of the CAD drawings include accurate measurements. The CAD models should include all of the required components listed in the project description.

www.robotshop.com/ca/en/ftdi-basic-breakout-5v-6-pin-header.html

www.amazon.ca/s/?ie=UTF8&keywords=ftdi+breakout&tag=googcana-20&index=aps&hvadid=174250598619&hvpos=1t2&hvnetw=g&hvrand=4026858980383774776&hvpone=&hvptwo=&hvqmt=b&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9001070&hvtargid=kwd-12630016726&ref=pd_sl_89y0s1qxpv_b

Orthographic Top and Side Views including Overall Dimensions

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hobbyking.com/en_us/hobby-king-quadcopter-power-distribution-board.html

www.amazon.ca/s/?ie=UTF8&keywords=quadcopter+power+distribution+board&tag=googcana-20&index=aps&hvadid=174194097525&hvpos=1t4&hvnetw=g&hvrand=3344574981872237996&hvpone=&hvptwo=&hvqmt=b&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9001070&hvtargid=kwd-37504097547&ref=pd_sl_8a9fsf3v5q_b

The following 3D CAD models are required for this drone quadcopter design. Each model will be 3D printed.

The precise measurements and details (engineering tolerances) of the CAD drawings ensure the proper assembly of the 3D printed parts and components, which will help to create the drone quadcopter without error. For example, the four-hole pattern of propeller cover (below) must align with the four-hole pattern of the arm (below) to allow for the motor mounting screws to fit.

RENDER IMAGESRender images create a photorealistic picture of the 3D CAD models.

3D CAD models assembled

Close-up of the propeller cover

Close-up of the arm

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DESIGN PROCESS: FORMALIZATIONIt is important to note different model fill settings are recommended when 3D printing the various components of the solar car. Small parts or parts with fine detail such as the landing gear, mounting plates and center plates should be 3D printed on the solid fill setting. Large parts such as the arms should be 3D printed on the sparse setting.

Note: To operate the drone correctly, distinguishing between the front and the rear of the quadcopter is necessary. This can be accomplished easily by 3D printing the two front arms and the two rear arms in different colors.

COMPONENTS BY WEIGHT

One important design consideration is the total weight of the drone quadcopter. Minimizing the total weight of the drone ensures proper operation and maneuvering capabilities. Consider the breakdown below when designing the drone. If there is a need to reduce weight, then modifications are required for the 3D printing components.

Note: To extend the life of the battery, consider reducing the overall weight of the quadcopter, while not compromising the strength and structure of the 3D printed parts.

PRE-OPERATION SET UP

After assembling the drone and charging the battery, the controller board and radio transmitter require set up. Arduino 1.8.0 Windows was selected as the software for this drone project.

Arduino is an open source, computer hardware and software company, project and user community that designs and manufactures microcontroller kits for building digital devices and interactive objects that can sense and control objects in the physical world.

This software can be downloaded directly from the Arduino website.

Arduino software www.arduino.cc

The following video offers instructions for the initial setup and configuration of the controller board.

www.youtube.com/watch?v=Zm8z4RLkFGU

COMPONENT QUANTITY WEIGHT (GRAMS)

Arm 4 170.0

Top Plate 1 42.2

Middle Plate 1 29.9

Bottom Plate 1 37.1

Electric Motor and propeller

4 270.8

Battery 1 222.70

Receiver 1 8.6

Screws 16 5.6

Landing gear 4 45.0

ESC 1 30.3

Propeller Cover 4 25.5

Center Stands 1 28.4

Total Weight: 916.1 grams or 2.0 lbs.

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SETTING UP THE RADIO TRANSMITTER

The following website and video (indicated below) provide instructions to set up the radio transmitter.

learnrobotix.com/uavs/quadcopter-build/fpv-racing-quadcopter/how-to-build-a-fpv-racing-quadcopter-setting-up-the-Fly-Sky-FST6-radio.html

www.youtube.com/watch?v=amDe_CPrKSg

THE ADVANTAGES OF 3D PRINTING

The drone quadcopter project illustrates one of the benefits of 3D printing. 3D printing allows students to continuously assess and refine their designs based on real-world testing. For example, the first prototype of the arm was found to not be strong enough for landing. The second design, in yellow, illustrates a solution to the problem. The final design, the top image, shows the arm re-engineered with the modifications. Note also the modifications made to the landing gear.

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GLOSSARY OF TERMSDrone language may be confusing for beginners. This is a small glossary put together to help you understand the more commonly used terms in the drone world.

Auto leveling: This mode allows the drone or quadcopter to level even in flight. This is usually an automatic feature that gets engaged through the push of a button.

Center of gravity: This is the location where most of the quadcopter’s weight is positioned. The center of gravity has to be positioned almost perfectly in the center of the UAV. It is the determining factor for leveled flight and more stability in the air.

Drone: An unmanned aerial vehicle (UAV) that’s usually piloted from the ground. It could carry a camera or it can simply be used for fun.

Electromagnetic interference (EMI): Any disturbance that could potentially affect the control of the UAV is known as EMI. EMI of any kind can make it impossible for a human to pilot the drone from the ground. All kinds of electromagnetic radiation could interfere with the piloting of UAVs.

FAA: The Federal Aviation Administration regulates and oversees American civil aviation.

FC: The Flight Controller is used to control the UAV.

First person view (FPV): This technology = allows the person controlling the drone to observe the flight as if they’re in the aircraft. FPV is possible because the camera footage from the drone or the quadcopter is observed in real time. Most often, FPV footage is viewed on a tablet or a smartphone. Some drone models could have specialized goggles for the purpose.

Fly away and fly-away protection: This refers to UAV flight that’s not controlled by the pilot. Fly aways are often caused by EMIs. Some UAVs come with fly-away protection systems. In case of loss of control, the drone’s GPS location system can make it return safely to the start position.

Gimbal: This gadget is used to stabilize the camera so that the video remains stable when flying.

Global positioning system (GPS): This is a navigation system and most UAVs come equipped with it. GPS makes it easy to always have an accurate idea of the drone’s location. The positioning system also allows for the return home functionality.

Hexacopter: This UAV has six horizontal propellers.

Gyroscope: This device consists of either wheels or discs, enabling it to spin around its axis. A UAV that has a camera with a gyroscope will typically be capable of shooting steady footage.

Line of sight: also known as LOS, this refers to being capable of seeing the UAV in the air. For safe use of a drone or a quadcopter, it should always be within the ground controller’s line of sight.

Mount: This is used to attach a camera to a drone.

No fly zone: This term refers to areas that have governmental restrictions disabling the flight of UAVs above the region.

Over the horizon: This is a situation in which the UAV is outside the controller’s line of sight.

Octocopter: This UAV has eight horizontal propellers.

Payload: This measurement refers to the amount of additional weight that UAVs can carry. The payload usually refers to the weight of the camera because that’s the additional equipment most often installed.

Pre-Flight Planning: This is used to pre-program flight path.

Point of interest: This is the place that a UAV is supposed to reach. Alternatively, a point of interest could be any area of which the camera on the UAV is supposed to capture footage.

Quadcopter: This UAV has four horizontal propellers. Because of this characteristic, a quadcopter is typically capable of more stable flight than a helicopter.

Radio controlled (RC) aircraft: RC aircraft or UAV refers to a drone or a quadcopter that is radio controlled from a distance.

Ready to fly (RTF): This refers to drones and quadcopters that come completely assembled. Such devices are literally ready for use once they’re taken out of the box.

UAV: This acronym that stands for unmanned aerial vehicle. This is a device that’s capable of movement without having a pilot on board.

Yaw: This term refers to movement of the drone counterclockwise or clockwise.

2.4 GHz: This is the most commonly used radio frequency rate for drone controllers.

Glossary Reference: Young, Jesse. “Latest News.” DroneGuru. N.p., 27 Mar. 2017. Web. 05 Apr. 2017.

LAWS AND REGULATIONSDo keep in mind there are some laws regulating the operation of hobby RC UAVs and drones. Please consult your local regulations before operating UAVs. Also stay safe! High flying objects with high speed propellers and inexperienced pilots can cause a lot of damage to people and property.

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To access additional 3D Learning Content and resources visit: http://www.stratasys.com/education

ACKNOWLEDGEMENTSStratasys would like to express our deep appreciation to Mike Santolupo, design teacher at John Paul II Catholic Secondary School in London, Ontario, for his valuable and constructive contributions to the toolkit and related project modules. His expertise, experience and eagerness to promote 3D printing in the classroom have been essential to developing this resource for teachers everywhere.

LEVEL 1(60-69%)

LEVEL 2(70-79%)

LEVEL 3(80-89%)

LEVEL4(90-100%)

Knowledge/understanding

3D drawing concepts

3D CAD drawings are incomplete or illegible. Dimensions are not present; 3D design features and tools have not been used

Dimensions are used inconsistently. There is limited use of 3D design features and tools covered in class.

Most dimensions are present and meet the design criteria. Most 3D design tools and features have been used properly.

All dimensions are present and meet the design criteria. All 3D design tools and features have been used correctly.

Thinking/inquiry

Level of complexity

Drawings consist of basic shapes that do not challenge the student’s design skills.

Drawings consist mostly of basic shapes with few elements that challenge the student’s design skills.

Drawings contain some elements that will challenge the student’s design skills.

Drawings contain complex shapes that will challenge the student’s design skills.

Application

Design integrity

Final product does not resemble original scaled sketches

Final product reflects a few elements of the original scaled sketches.

While some relatively complex features could not be accomplished, the final product reflects most elements of the original scaled sketches.

Despite some relatively complex features, the final product closely resembles the original scaled sketches.

LEVEL 1(60-69%)

LEVEL 2(70-79%)

LEVEL 3(80-89%)

LEVEL4(90-100%)

Knowledge/understanding

Design criteria

Student met none of the design criteria outlined in the Project Description.

Student met some of the design criteria outlined in the Project Description.

Student met most of the design criteria outlined in the Project Description.

Student met all of the design criteria outlined in the Project Description.

Thinking/inquiry

Creativity, originality and design considerations

The student’s product is unoriginal, borrowing largely from other sources. Student cannot explain their design decisions.

The student’s product is simple and predictable, or borrows mostly from other sources. Student cannot satisfactorily explain their design decisions.

The student’s product is unique and demonstrates independent thought. The student can explain their design decisions.

The student’s product is highly imaginative. They incorporate surprising or elaborate features that reflect creativity and personality, and can explain their rationale.

Application

Appearance

Final product does not work as expected, and student has not improved the design over multiple iterations.

Final product does not work as expected, but the student has improved the design over multiple iterations.

Final product works as expected and student has improved the design over multiple iterations.

Final product works as expected, and student has made novel or innovative improvements over multiple iterations.

DRONE QUADCOPTER